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Kupe's Zodiac 650B
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Date:  6-21-2014
Number of Hours:  2.00
Manual Reference:  6-C-1
Brief Description:  Forward Top Skin 4

Today I fashioned two gussets out of .025 aluminum (left over from trimming the fuselage skin). The gussets run from just forward of the canopy side frame bolt to ~100mm in front of the firewall. The purpose of these two gussets is to provide a means of forming a permanent attachment between the upper fuselage skin/upper longeron and the upper firewall, but without requiring a permanently attached forward top skin. The gussets are attached to the lower fuselage (upper longeron) by 3 A5 rivets in the same manner the top skin would be in the normal plans. The gussets are also attached to the firewall by an additional 3 A4 flush mount rivets. I also added 1 A4 rivet to connect each gusset to the forward end of the panel side angles for additional rigidity.

The gusset covers 4 of the countersunk nut plate attachments so I match drilled the gussets to take this into account then dimpled them to maintain the flush fit for the screws and washers. I also made sure the gussets didn't cover the bolt holes used as pivot points for the forwad portion of the canopy.
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Left side gusset from the front. Screws and tinnerman washers in place to check fit.

Left side gusset from the front. Screws and tinnerman washers in place to check fit.

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Right side gusset with fit being checked. Note the pivot bolt just aft of the gusset.

Right side gusset with fit being checked. Note the pivot bolt just aft of the gusset.

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